That sounds like a very odd issue. I had to go through 3 Sigma 30s to get a properly focusing one, but the first two were fine at close distances and horrendously frontfocused on anything over 6-10 feet away. It was totally worth sending back for another. Yours sounds quite inconsistent, so I'd return and get another...if you get one that just has simple backfocus or frontfocus issues, then send that to Sigma and they'll fix it for you (or you can have them try and fix this one too, if you like).
Again, though, this lens is worth the hassle. Second only to the 35L optically in this range, and it isn't far behind.